Inorganic building system



Feb., 22, 1938. I Ml FOSTER 42,109,265 y I INoRGANIc U1LnI NG SYSTEM i Filed Aug. '20, 1935 Z'Sheets-Sheet 1 Feb. 22, 1938. M. FQSTER 2,109,265

INORGANIC BUILDING SYSTEM Filed Aug. 20, 1935 A 2 Sheets-Sheetl 2 BY` Zo il l Amm/EY.

Patented F eb. `22,

UNITED STATES 'PATENT ,l OFFICE The invention relates to a new method and new means for the preparation ofthe parts for and for the erection of buildings, and the ob jects of the invention, among others, are to provide for a structure composed entirely of inorganic materials, and withA all metal used entirely embedded in and protected by an encasment of inorganic materials, thus making a structure indestructible, and to provide novel l0A means for assembling and uniting the parts of `such structure.

I attain these objects in the manner and by the method herein described, and illustrated in the accompanying drawings, in which- Fig. 1 is a perspective showing the wall and lower iioor construction;

Fig. 2 is a perspective showing upper oor,

ceiling, and roof constructiom' Fig. 3 is a horizontal section showing the assembly of the wall column and wall construction;

Fig. 4 is a vertical section showing t e assembly and construction of the beams wit oor and ceiling elements;

Fig. 5 is a horizontal section through the walls and a plan View showing the relations of the wall partsand of the interlocking floor pieces;

Fig. 6 is a vertical section through the .beams splines 3 and anchor slots 4 for securing the in` 40 side face pieces or wall boards 5. the wall posts 6 with their metal cores 1 with the slots for splines 3, 8, the iloor pieces 8 and their interlocking joints I0,.the ceiling pieces II, and the" corner posts I2.

.45 Fig. 2 shows the wall pieces 2, the corner post I2, the roof and eaves piece I3, I3 respectively, the roofing pieces Il, the roof beam I5 which is similar in construction to the :door beam and the horizontal metal tie piece I6 joining the heads 50 of the wall posts.

Fig. 3 shows'the wall post 6, the metal core of wall post 1, the splines 3, the anchor slots 4, the inside face pieces 5 and thehorizontal pipe slots I1 in the inside face of the wall 55 pieces.

posts and wall.

Fig. 4 shows the beam 8, the bottom block 2li, the side I8, the imbedded metal I9, the ceiling piece I I, the hoor piece 9.

Fig. 5 shows the wall pieces 2, the wall posts 6, the corner post I2, the splines 3, the anchor slots 4, the iloor pieces 9 and adjacent parts.

Fig. 6 showsthe wall pieces 2, the pipe slots I1,

the beam 8, the beam bottom blocks 20, the beam iloor pieces 9 and the ceiling pieces form tothe contour of the post cross section.

Fig. '7 shows the wall pieces 2, the pipe slots I 1, the floor pieces 9, showing the side interlocking joint 2| and the ceiling pieces II.

Fig. 8 shows the wall pieces 2, the pipe slots I1, theyimbedded metal I9, I 9 the horizontal tie joining the heads of the posts I6, the'anchor rods 22, the splines 3 and the metal beam template 23.

This method makes the greatest possible use of allthe structural materials entering into the construction of the building; all material inthe completed structure is working and all parts are proportioned to the stresses coming upon them. For instance where encasing material requires a safe working unit for stress of 400 lbs. per square inch, it is made up to that desideratum; if 120 lbs. unit stress is required it is so made. 'I'he imbedded metal is placed and designed in detail to take care of the forces acting upon it. Therefore as all materials are working, there is no substantial useless dead weight anywhere. In

. this combination of correctly prepared and proportioned materials with a complete freedom to the architect in his designs liesan element of novelty and 'this alsoxmakes posible the construction of a really iireproof 'housing or other building at a cost not greater than the cost of areasonably well built wooden frame structure.

'Ihe various elements entering into the struc*Y ture are preferably made yof porous concrete, the use of the concrete having a predetermined proportion of voids, according to strength and weight requirements being contemplated, an j his ls reinforced by steel bars or other elements, such as 'those shown at 1 and I9, imbedded therein and extending tothe extremities of such elements which engage with other elements. The saidV elements are molded in suitable adjustable forms giving them the desired size,- proportions and detalls of form. The dimensions of the elements may, however, be varied by adjusting the forms and as each floor and ceiling. is laid, the, slurry and posts of any required length and having anyl desired width and thickness may be molded to suitthe size, proportions and required'strength of a the building and embody infinite variationstin architecture, andl in this molding pl'OCeSS the illustrated steps. Vianges, and slots or grooves' for fitting the parts together and joining them and for the reception of keys or splines are formed,` while the metal reinforcement cut to the required length is imbedded therein. The said elements are also preferably cast hollow to reduce their weight, provide insulating air spaces ,and also provide for the housing therein of pipes, wires, etc., and furnish airconduits.

When the umts or elements are fitted together the joints are filled with a thin slurry which fills all interstices and unites them to form a unitary structure. 'I'his is preferably done as each course being poured in between the joints and allowedto spread over theabutting surfaces. An expansible slurry. of known formula, is used for this purpose, so that when it sets itwill exert a certain degree 'of pressure on such surfaces and unite therewith. Where splines or metal tie pieces or the like are used, the interstices between them and the adjacent surfaces will also be filled -with slurry.

'I'he frames for doors, windows and other openings are formed in the same manner asthe other parts herein described.

The designs of any competent architect can be carried out, in,Y any exterior or interior materials desired. In`p1anning the architect need give no considerationto the structural elements, or the modules, which govern the plan in prefabricated or factory made houses, thus permitting the design-of buildings wholly for service, convenience andA beauty, the methods used in the preparation of the parts being so flexible that no rigidly sized or proportioned` elements dictate the design. Y I

l As all material elements entering into the design are inorganic, and as all chemical reactions are completed during the preparation processes,

the structure may be regarded as indestructible by the elements of fire, air and water, and for the samereasons the structure/'is immune from destruction by insects or vermin.

The becomes homogeneous and owing to the cellular qualities in the encasingmaterials used, to the hollow and sealed design ofthe walls, noon and roofs, and to the com'- plete imbedment of the encased steel, sound .transmission is verylow, and for the same reasons,heat loess and heat communication from v' the exterior IU conduction are at a Noforms are required inthe construction on the Prepared folmdation which may-be of any suitable Preparation is ma'de inthe structure for' the installation of any or all types of modern equipment-such as plumbing, heating, airconditioning,dectricity, etc. m

No forms or tool'are needed for the erection, and no nails, bolts, screws another fastening means. Norisitnecsaarytoct, work,bore, perforate or otherwlse'operate upon the units Aor elements employed. .It will be seen also thatthe said elements are so formed that when' fitted together they imite and cooperate to' resist weight, stressesandstrainsinalldirections. Themethod being essentially Va dry process, the of ex`uding moisture so detrimental in the cest type of structure are avoided. 'I'he constructive procedure, being on a preferred foundation, is as follows: First lay the first course of the wall pieces, these being so shaped that they form a placement template for the setting of the floor beams and wall posts. Then set the floor beams, then the interlocking ceiling pieces, which are so 1 designed that workmen may in safety lay all con- ,duits, pipes and ducts before the floor pieces are placed. Then set the posts, and the pieces in the outer walls, these being so designed that their placement and the setting of the splines automatically trues the vertical position of the wall posts in all directions. Place at this time the frames in the door and window openings; s etthe metal horizontal ties at the tops of the wall posts; then the second tier of beams; then ceiling pieces. Proceed in the same manner with the building of the upper stories. Set the upper floor beams, the ceiling pieces, the roof rafters and the roofing pieces. When pipe and wiring and duct work is complete lay the interlocking floor pieces,

vthen the interior partitions, and therinner surface of the outer walls.

.This method is accurate and rapid. No heavy pieces have to be handled,- and immediately on completion the structure is ready for use andv occupancy. Buildings of one, two, three or more stories may be erected, the design and construction of the wall posts and ties being modified to suit the height of the building. y

What I claim is: l. A building frame comprising molded units or elements of mineral material, embedded metal reinforcements therein, said units being of various sizes, dimensions and shapes, portions thereon and atdiflerent parts thereof shaped to inter-- lock with complemental portions of other similar and dissimilar units, said portions being brought together and united by sa'id complemental portions without other fastening means to form the building construction, a cementitious substance .lock with complemental portions o'f other sinilarv and dissimilar units, said portions being brought together vand united by. said complemental portions without other fastening means to form the,v

building'construction, a cementitious substance' between certain of said portions at their abutting surfaces unitingv such surfaces and metallic key members inserted between certain "other of said portions and engaging said abutting surfaces, certain of the said abutting surfaces having receases therein for the reception of such key members, and certain oi' said units also having reoesses therein extending -across the `same and forming with the recesses of adjacent units contlnuous ducts or voids. f

. L 3. "A building frame construction comprising beams, floors, posts, walls and other parts of in- -units` to unite them whencassembled to forniv a building frame, metallic splines inserted between divldual molded units of 'mineral material, lSaid d engage with complementa] portions of other' units to unite them when assembled to form a `building frame, metallic splines inserted between said portions. the said portions having complemental recesses to receive said splines, and metal plates inserted between ends of post sections and 5 interposed beam ends.

MOR'I'IMER FOSTER.. 

